FJ62 Hard Start & Gas Smell After Shut Off

[SAR_Squid79]

This problem started very suddenly yesterday...

First off, for a few weeks now, I've had a check engine light.
Codes:
25: - Air Fuel Ratio Lean Malfunction
26: - Air Fuel Ratio Rich Malfunction

I thought it was the o2 sensors, but just haven't got around to replacing them yet, as the Cruiser still ran fine. About 6 weeks ago, my Fuel Pump died, and I replaced it, everything was good to go . . . a couple of weeks later I got the CEL . . . now this.

Yesterday morning, my Cruiser started up just fine; 1 turn of the key as usual. At lunch time it started fine, I went out for lunch, then after lunch it was a little hard to start (had to crank it over 2 good times). Once it's started, it runs just fine. As smooth as always. After you cut the truck off, you can smell a very strong gas smell. It seems to be coming from the driver's side of the engine bay. Now every start is hard - it has to be cranked over 2 or 3 times to start, and gives off the strong fuel odor after every shut down.

I'm thinking Fuel Pressure Regulator is where I should start. The FSM also mentioned some kind of Check Valve... And I've read a lot about this pulsation dampener.

#1: Does this sound about right to you guys?
#2 Do you guys think that this could be the REAL source of the CELs? ...not faulty 02 sensors?

Opinions please!!! If you've got one, let me hear it!!!

 

[Benjaman]

When you say 2 or 3 times to start, do you mean the engine rotates 2 or 3 times or do you mean the key is released and turned again 2 or 3 times?

This problem started very suddenly yesterday...

First off, for a few weeks now, I've had a check engine light.
Codes:
25: - Air Fuel Ratio Lean Malfunction
26: - Air Fuel Ratio Rich Malfunction

I thought it was the o2 sensors, but just haven't got around to replacing them yet, as the Cruiser still ran fine. About 6 weeks ago, my Fuel Pump died, and I replaced it . . . then I got the CEL . . . now this.

Yesterday morning, my Cruiser started up just fine; 1 turn of the key as usual. At lunch time it started fine, I went out for lunch, then after lunch it was a little hard to start (had to crank it over 2 good times). Once it's started, it runs just fine. As smooth as always. After you cut the truck off, you can smell a very strong gas smell. It seems to be coming from the driver's side of the engine bay. Now every start is hard - it has to be cranked over 2 or 3 times to start, and gives off the strong fuel odor after every shut down.

I'm thinking Fuel Pressure Regulator is where I should start. The FSM also mentioned some kind of Check Valve... And I've read a lot about this pulsation dampener.

#1: Does this sound about right to you guys?
#2 Do you guys think that this could be the REAL source of the CELs? ...not faulty 02 sensors?

Opinions please!!! If you've got one, let me hear it!!!

 

[SAR_Squid79]

When you say 2 or 3 times to start, do you mean the engine rotates 2 or 3 times or do you mean the key is released and turned again 2 or 3 times?

Key turned . . . cranks, no start, key released.
Key turned . . . cranks, no start, key released.
Key turned . . . cranks, starts, runs fine.

 

[hi90]

have you checked your pulsation dampener fuel often leaks from this

 

[SAR_Squid79]

No - I haven't checked it yet. I have never heard of it until I was searching the forum yesterday.

Anybody got a pic? ...or a page in the FSM?

 

[SAR_Squid79]

This thing?

 

[hi90]

on a 62 its facing up at back of fuel rail it is a mother to get out I had to loosen the intake manifold so I could get a wrench on it and make sure you get new copper O rings for it

 

[SAR_Squid79]

Does anybody have a part number or anything?

 

[SAR_Squid79]

I just checked with Toyota, and they can't find any "Pulsation Dampener" in the parts list. Is that the actual name for it? Can anybody else point me in the right direction where to get one?

 

[SAR_Squid79]

Upon further inspection and troubleshooting this morning, I have confirmed that this is definitely the source of my problem! IH8MUD saves the day again - because I doubt if I would have ever found that little son of a bitch on my own. It's wierd to me that this part could have gone bad and started leaking so suddenly... Maybe it'll make more since once I get it off the truck, and can look at it closer.

Now I just have to figure out where to get a replacement.

I snapped a couple of pics of this pesky Pulsation Dampener - that will maybe help somebody out in the future. This thing is definitely going to be a PITA to get to.

 

[ad20k]

I just checked with Toyota, and they can't find any "Pulsation Dampener" in the parts list. Is that the actual name for it? Can anybody else point me in the right direction where to get one?

I just put one on order from 1sttoyotaparts. I got these numbers by cross referencing toyodiy with the fj62 manual. I hope they are right.

23207‑74010 pulsation dampener
23232‑28010 upper gasket
90430‑12005 lower gasket

 

[SAR_Squid79]

THANKS!

...I'll email those PNs to my parts guy, and see if he can get 'em!

 

[hi90]

you might want to check your fuel regulator sometimes when the pulsation pops its because the regulator went out it can also lead to a fuel pump malfunction. You need a vacuum gauge for this and specs.

 

[mcrty23]

You need to find a different Toyota Dealer if he can't find you the part, Fuel pulsating dampener, which is most likely your problem. It took me several days to locate my fuel leak I had, it was the fuel pulsating dampener at the rear of the fuel rail. I have a F62, and to replace it, I had to bend a wrench to get to the thing. Make sure you put new washers, and get them from Toyota too. If you don't put them in the right order, you will have problems as well. Good luck!

 

[SAR_Squid79]

I got with my parts guys today and ordered the Pulsation Dampener - it was a slightly different part number than posted above. Part Number: 23207-46010

I also got the 2 crush collar gaskets, and I went ahead and pulled the trigger on the Fuel Pressure Regulator.

 

[4runner4ever]

let us know how this turns out!

 

[slcfj62]

I used a crows foot wrench to remove and install the pulsation dampener. I don't know how you would do it otherwise. And I also replaced the FPR at the same time. Fixed an engine miss when I did. I think those two items should be replaced as a maintenance item--don't wait til they fail.

 

[SAR_Squid79]

I used a crows foot wrench to remove and install the pulsation dampener. I don't know how you would do it otherwise.

That's exactly what I was thinking of trying!

I'll definitely post install pics.

 

[SAR_Squid79]

I ordered the parts from ToyotaPartSales.com - Toyota of Dallas was awesome AGAIN! Thanks Jaques!

I ordered:

PN:_______________Name:
23207-46010.......Pulsation Damper
23232‑28010.......Upper Gasket
90430‑12005.......Lower Gasket
23280-61010.......Fuel Pressure Regulator
90430-08014.......Fuel Pipe Gasket (2)





I ordered the Parts on Tuesday, and they were sitting on my porch when I got home on Friday.

Because of where the Pulsation Damper is located, you have to either buy or improvise a 22mm Crowsfoot Wrench. I found my local Snap-On guy and bought the wrench.

I replaced the Fuel Pressure Regulator first. It's pretty straight forward.
The 2 bolts that hold the regulator to the bracket, are a little bit of a pain to get to. I just loosened them until I could unscrew them with my fingers. The "Fuel Pipe" (Banjo Bolt) is easy.











--TORQUE to 13 LB-FT--



--ALL DONE--

​

Next I set about what I thought was going to be a difficult task. The hardest part turned out to be just getting up on top of the engine so that I could get the Crowsfoot Wrench, extension, and ratchet on the Pulsation Damper. Once I got up to where I could see and reach everything, it wasn't very difficult at all.

This is the little bastard that was leaking fuel like a sieve:



The Pulsation Damper is on the back of the engine block, at the end of the fuel rail, near the firewall, below and behind the Intake Maniford. It's a BITCH to get ahold of!





When putting the new Pulsation Damper on, the silver gasket with the teeth goes on the Pulsation Damper itself, and the regular round copper gasket goes underneath the Banjo fitting. That's a bit of a PITA, because there's only about 1/8" of play in that banjo. BE CAREFUL NOT TO CROSS-THREAD!





--ALL DONE--​

She started right up, ran nice and smooth, and the fuel smell is GONE!!!

*Note - On top of the pulsation damper, there's a little set screw. That screw is set by Toyota for proper function, and should never be tightened by the end-user. When I removed the old pulsation damper, the screw fell out completely. Just for the hell of it, I tried to screw it back in, and could not. This must have been the source of the problem.

 

[mcrty23]

Ya, my dampener did the same thing, the screw was just sitting on top and the plastic cap kept it from going anywhere. Glad to here you got it all fixed up, and correctly too!!! Nice job!!